Paint Process Optimization Specialist

4 weeks ago

Brownsville, Texas, United States Blue Bird Full time
Job Summary

The Paint Process Optimization Specialist will support the Blue Bird Paint Operations Team in optimizing surface treatment and paint processes to meet operational targets for Safety, Quality, Cost, and Delivery.

This role will be responsible for supporting both manual and robotic spray paint operations, including graphic user interface on electrostatic paint application, robotic pathing, robotic fluid delivery systems, fault recovery procedures, and troubleshooting.

Robot safety will be a paramount issue, along with pathing adjustments such as logic, software, and path alterations through either off-line or on-line methodology, teach pendant operation, and data program entries.

Key Responsibilities
  • Provide technical direction and management of the design, improvement, and installation of integrated systems of people, materials, and equipment.
  • Lead continuous improvement projects to improve processes.
  • Lead the development of operating systems used in the paint shop for application of surface pre-treatment, electrocoat, primer, and topcoats.
  • Highly technical paint robot programming, paint application, and technical expertise in robot troubleshooting.
  • Continuously and incrementally improve all manual spray and robotic spray processes and document as standardized work.
  • Minimize robotic downtime by systematically and proactively monitoring part performance and spare part status; prioritize schedule of immediate replacement with emphasis on most troubled robots.
  • Develop and refine shift reports for immediate post-shift review; recommend and implement data analysis techniques to refine understanding and production processes and pursue real-time reporting and decision making.
  • Collaborate with and/or direct plant personnel, contractors, and equipment suppliers in repair/improvement work.
  • Prioritize work/improvement schedule to support annual shutdowns for Preventive Maintenance, 5S, and equipment updates.
  • 24/7 availability for consultation is required.
  • Establish manual spray and robotic spray training requirements and programs for Production and Maintenance personnel.
  • Support Paint Operations team in setting goals and measuring key indicators of plant performance for Safety, Quality, Cost, and Delivery.
  • Support Paint Operations Team with optimization of waste elimination, quality improvements, operating system controls, material flow, footprint development, and efficiency improvements.
  • Support Paint Operations Team in capital budgeting/improvements, equipment requests, process improvements, scheduling, and project management as required.
  • Ensure development and compliance of ISO documented processes.
  • Coordinate the smooth implementation of production changes as required.
  • Maintain a current knowledge level of emerging concepts, techniques, and technologies related to our processes to provide future guidance and vision for improving existing integrated manpower, methods, and machines.
  • Lead Team activities focused on new processes and facility initiatives related to the Paint Shop.
  • Lead and participate in Continuous Improvement activities, including PDCA, Kaizen Events, and Structured Problem Solving.
  • Support Environmental Health and Safety team by implementing and maintaining VOC monitoring controls for paints and solvents. Review product material data sheets for new paint and solvent material to ensure adherence to specifications.
Requirements
  • Mastery of paint process and equipment transfer efficiency, quality checks, and verifications.
  • Detailed knowledge of paint application equipment, pre-treatment systems, paint shop productivity improvement practices, tools, and methods.
  • Ability to effectively develop a vision, plan, and coordinate the activities of the Paint Technicians with the Paint Operations Team.
  • Mastery of back-up and restoration of all robot programs with paint parameters and fluid presets.
  • Demonstrated advanced level experience with troubleshooting, problem-solving protocols, and techniques, visual aids, and production control boards.
  • High level of demonstrated computer skill proficiency, including but not limited to, Microsoft Office (Excel, Word, PowerPoint Presentations), robot programming, and adjustments for trouble-shooting initiatives.
  • Ability to take the lead through hands-on activity.
  • As all documentation is in English, proficiency in the English language is required.
  • Demonstrated ongoing continuous education in computing systems, hardware/software structure, while recognizing the limitations and creating improvements of the existing robotic process systems.
Education and Experience
  • BS Degree(s) in Industrial, Chemical, Mechanical, or Electrical Engineering or equivalent.
  • Minimum of 8 years of experience in a Tier One Parts, or OEM Automotive Paint Shop operation.
  • Experience in utilization of mechanic aptitude for performing any mechanical component repair or replacement, in addition to having knowledge of PLC communications and other robotic peripheral equipment.
  • Experience with Fanuc robots and programming preferred.
Work Conditions

(The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this job. Reasonable accommodations may be made to enable individuals with disabilities to perform the essential functions.)

Office environment and production environment.

Must work in manufacturing environment with exposure to heat, cold, and noise.

Fast-paced production area with moving objects and sheet metal.

Occasional periods of standing or sitting for extended periods of time.

Must wear appropriate PPE when and where required.

Frequent weeks working 40+ hours.

Frequent communication with people throughout the day.

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